Snap-in pedal with end caps

ABSTRACT

A mounting for a control pedal in a motor vehicle includes a mounting bracket fixed relative to the vehicle having apertures defining an axis of rotation. The pedal has a hub defining a pivot axis. Spring loaded bearings in the hub are adapted to automatically snap axially outward from a first position to a second position, thereby rotatably connecting the pedal with the bracket, when the pivot axis is aligned with the axis of rotation. The axes are aligned by manipulating the pedal. Pedal end caps are snapped onto the hub and interposed between the hub and the bracket.

This application is a continuation-in-part of U.S. patent application Ser. No. 08/086,418, entitled "Snap-In Pedal", filed on Jul. 2, 1993, assigned to the assignee of this application, now U.S. Pat. No. 5,398,569, issued on Mar. 21, 1995. This invention relates to foot operated control pedals for use in motor vehicles.

BACKGROUND OF THE INVENTION

Typically, foot operated control pedals in motor vehicles, particularly those for the brakes and the clutch, are rotatably mounted to a bracket in the vehicle by aligning a pivot axis of the pedal with an axis of rotation of the bracket, and passing a bolt through apertures defining those axes. It is also known to pass the bolt through bushings and spacers disposed between the bracket and the pedal. The bolt is tightened, and the pedal pivots about the bolt.

The use of an axially inserted bolt or shaft has two disadvantages. One is that this method of assembly is inherently difficult because three to four items must be simultaneously axially aligned by an assembler. A second disadvantage is that it is necessary to reserve a large amount of access space for the axial insertion and removal of the bolt. Other disadvantages relate to the use of a threaded fastener. A significant amount of time is required to thread the nut and bolt together. It is also necessary to provide equipment controlling the assembly torque of the joint.

Alternative mounting means to bolts are found in the prior art, but they share the disadvantages of axial manipulation of the mounting means to rotatably secure the pedal to the bracket. It would be desirable to provide a mounting for a control pedal which rotatably connects the pedal with the bracket by merely manipulating the pedal relative to the bracket to align the pivot axis with the axis of rotation. It would also be desirable to provide a mounting including bushings or spacers disposed between the bracket and pedal which are simultaneously assembled by merely manipulating the pedal relative to the bracket.

SUMMARY OF THE INVENTION

This invention is a new and improved mounting for a control pedal in a motor vehicle. The mounting includes a mounting bracket fixed relative to the vehicle with means defining an axis of rotation. The pedal has means defining a pivot axis. A snap-in connecting means between the pedal and the bracket is adapted to automatically shift a bearing axially from a first position to a second position, thereby rotatably connecting the pedal with the bracket. This occurs when the pivot axis is aligned with the axis of rotation by manipulating the pedal. This pedal mounting significantly reduces the amount of time needed to install a pedal in a motor vehicle. It also reduces the number of parts needed to mount a pedal in a motor vehicle. Pedal end caps are snapped onto the pedal and are disposed between the pedal and the bracket to provide smooth and quiet operation of the pedal.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a front view of a pedal assembly disposed just below a bracket.

FIG. 2 shows a front view of the pedal assembly with bearings disposed in a lead-in channel.

FIG. 3 shows a front view of the pedal assembly installed in the bracket.

FIG. 4 shows a side view of an installed pedal assembly in an apply position, and in a release position in phantom.

FIG. 5 shows a front view similar to FIG. 3 of another embodiment of the pedal assembly installed in the bracket and including pedal end caps.

FIG. 6 shows a perspective view of the pedal end cap of FIG. 5.

DESCRIPTION OF THE PREFERRED EMBODIMENT

A mounting 10 for a clutch control pedal 12 for use in a motor vehicle according to this invention, includes a bracket 14, the pedal 12 and a connecting mechanism 16 rotatably connecting the pedal 12 with the bracket 14. The connecting mechanism 16 of this embodiment has been integrated with the pedal 12 into a pedal assembly 18.

The bracket 14, fixed to the vehicle, has a pair of laterally spaced apart, axially aligned apertures 20 in opposed flanges 22 defining an axis of rotation 24 on the vehicle. The bracket flanges 22 each have a facing lead-in channel 26 approximately equal in width to a diameter of the apertures 20 with the distance between bottoms 28 of the channels 26 tapering from a maximum at the edges 30 of the bracket 14 to a minimum at the apertures 20.

The pedal 12 is formed of steel with a rubber foot pad over a first end 32, a pivot axis 34 at the second end 36, and a link pin 38 disposed therebetween.

The connecting mechanism 16 of the pedal assembly 18 includes a steel sleeve acting as a hub 40 axially centered on and rigidly fixed to the pedal 12 and defining the pivot axis 34. The connecting mechanism 16 also includes a pair of identical piston-like bearings 42 disposed within the hub 40. The bearings each have a spring pocket 44 in their facing surfaces 46. A helically coiled compression spring 48 is disposed between the bearings 42 within the spring pockets 44 and forces the bearings 42 apart.

The length of the hub 40 is dependent on the cumulative length of the bearings 42 and the spring 48. An inside diameter A of the hub 40 is larger than the apertures 20 in the bracket 14. Dimples 50 in the hub 40, one on each side of the pedal 12, locally reduce the inside diameter of the hub 40 to limit the travel of the bearings 42 into and out of the hub 40, as explained in more detail below.

The bearings 42 are made of plastic. The bearings 42 are cylindrical and are made as long as practicable to help maintain them coaxial with the hub 40. The diameter of the bearings 42 varies stepwise along their length from a first full diameter portion 52, to a first reduced diameter portion 54, to a second full diameter portion 56, and to a second reduced diameter portion 58.

The first full diameter portion 52 is sized to freely rotate inside the hub 40, and has a short length. The first reduced diameter portion 54 is sized to clear the dimples 50 in the hub 40, and has a length equal to the expected travel of the bearing 42 in the hub 40.

The second full diameter portion 56 is sized to prevent entry into the bracket aperture 20 yet freely rotate inside the hub 40, and has a length sufficient to keep a bearing load per unit of area at or below a magnitude which can be sustained by the plastic. The second reduced diameter portion 58 provides a slight interference fit with the aperture 20 in the bracket 14 and has a length slightly longer than that of the bracket aperture 20. There is a chamfer 60 on an end of the second reduced diameter portion 58. The spring pocket 44 is at the first full diameter portion 52 end of the bearing 42.

The connecting mechanism 16 is assembled as follows. One of the bearings 42 is dropped into one end of the hub 40 with the first full diameter portion 52 being the first in. The second reduced diameter portion 58 of that bearing 42 extends out of the hub 42 and is pressed on to force the first full diameter portion 52 to snap past the dimples 50.

The spring 48 is placed in the other end of the hub 40 and received by the spring pocket 44 of the bearing 42. Another bearing 42 is placed, spring pocket 44 first, into the hub 40 and over the spring 48. This bearing 42 is pressed further into the hub 40, thereby compressing the spring 48, and snapping the first full diameter portion 52 past the dimples 50. The spring 48 is now captured between the bearings 42 and pushes them away from each other. The dimples 50 limit the outward travel of the bearings 42 in the hub 40 to a position where the second reduced diameter portions 58 extend beyond the hub 40. The pedal assemblies 18 would enter a vehicle assembly plant fully assembled.

At the vehicle assembly plant, the pedal assembly 18 is installed in the bracket 14 as follows. The pedal assembly 18 is gripped in one hand by an installer who manipulates it to align the second reduced diameter portions 58 with the lead-in channels 26 of the bracket 14. The bearings 42 are in an extended second position, fitting between the bottoms 28 of the channels 26 at the edges 30 of the bracket 14, as shown in FIG. 1.

The installer pushes the pedal assembly 18 in a direction normal to the axis of rotation 24 forcing the bearings 42 to move through the channels 26 and toward the apertures 20. The bottoms 28 of the channels 26 contact the bearings 42, gradually forcing them into a compressed second position, shown in FIG. 2, thereby compressing the spring 48. When the pedal assembly 18 reaches the installed position where the pivot axis 34 is aligned with the axis of rotation 24, the bearings 42 snap from the compressed position through the apertures 20 to the extended position shown in FIG. 3.

The entry of the bearings 42 into the apertures 20 is facilitated by the chamfers 60 on the bearings 42. The spring 48 forces the second full diameter portions 56 of the bearings 42 to seat against the flanges 22, overcoming the interference between the second reduced diameter portion 58 and the bracket apertures 20. With the bearings 42 thus engaged with the bracket 14, further movement of the pedal 12 relative to the bracket 14 is limited to rotary motion about the axis of rotation 24. The link pin 38 is subsequently connected to a clutch linkage 62.

When completely installed, the device works in the following manner. The clutch linkage 62 maintains the pedal 12 in an apply position B, as shown in FIG. 4. A vehicle operator rotates the pedal 12 to a release position C, shown in FIG. 4, by depressing it with his foot.

When the pedal 12 is rotated, the hub 40 rotates with the pedal 12 and the bearings 42 do not. The bearings 42 remain fixed with respect to the bracket 14 due to their interference fit with the apertures 20. The relative rotation between the bearings 42 and the hub 40 causes the second full diameter portion 56 inside the hub 40 to serve as a journal bearing, with its relatively large area keeping the bearing load per unit of area to the magnitude sustainable by the plastic chosen. When the operator lifts his foot from the pedal 12, the pedal 12 is restored to the apply position B by the clutch linkage 62. The bearings 42 continue to remain fixed with respect to the bracket 14 during the return to the apply position B.

It should be noted that the pedal mounting 10 of the present invention significantly reduces the cost of providing a control pedal in a motor vehicle by reducing the amount of time needed to install it, and by reducing the number of parts required for the pedal mounting. The present invention also increases the amount of usable space within the vehicle around the pedal mounting 10 by eliminating the need to provide clearance for axial insertion and withdrawal of the bolt.

FIGS. 5 and 6 show another embodiment of the mounting 10, similar to the embodiment shown in FIGS. 1-4, but having additional features. Similar features having the same description are denoted with the same numerals as used in FIGS. 1-4. In accordance with the embodiment in FIGS. 5 and 6, the hub 40 of the pedal assembly 18 includes radially outwardly flared end portions 70 and the pedal assembly 18 includes pedal end caps 80.

As best shown in FIG. 6, the pedal end cap 80 has an annular configuration and is integrally formed from a flexible plastic material. The pedal end cap 80 includes a conical-shaped head portion 82 and an outer skirt portion 84 extending axially from the head portion 82. An opening 85 through the head portion 82 has an inner diameter sized for closely capturing the second full diameter portion 56 of the bearing 42, as will be described further hereinafter. A plurality of longitudinal slots 86 extend partially through the length of the head portion 82 and entirely through the length of the outer skirt portion 84 to form a plurality of flexible spring segments 88. The spring segments 88 are each radially reduced adjacent the head portion 82 and then tapered radially outward.

The pedal assembly 18 is assembled separate from the vehicle in a manner similar to that described for FIGS. 1-4 with the addition of assembly of the pedal end caps 80 to the hub 40 as follows. Each of the pedal end caps 80 are axially aligned with the bearings 42 and the respective flared end portions 70 of the hub 40 such that the flexible spring segments 88 face the hub 40. The flexible spring segments 88 of the outer skirt portion 84 are manually slid over the bearings 42 and snap-fitted over the flared end portions 70 of the hub 40, thus connecting the pedal end caps 80 to the pedal assembly 18 without the use of tools. The combination of flexible spring segments 88 inwardly biased against the hub 40 and the flared end portions 70 of the hub 40 prevent removal of the pedal end caps 80 from the pedal assembly 18. Thus, the pedal end caps 80 are held on the pedal assembly 18 for assembly to the vehicle. After being snapped onto the pedal assembly 18, the pedal end caps 80 engage the hub 40 and rotate with the hub 40 and relative to the bracket 14. The pedal end caps 80 closely surround and rotate relative to the second full diameter portion 56 of the bearing 42 without interfering with the spring biased movement of the second reduced diameter portion 58 of the bearings 42.

The hub 40 with the snapped-on pedal end caps 80 has a length less than the lateral spacing between the apertures 20 of the bracket 14. Thus, the hub 40 with attached pedal end caps 80 may be easily installed normal to the axis of rotation 24, as will now be described.

At the vehicle assembly plant, the pedal assembly 18 is installed in the bracket 14 is the same manner as previously described. The pedal end caps 80 are simply carried on the hub 40 during manipulation of the pedal assembly 18 normal to the axis of rotation 24 and into alignment with the apertures 20 of the bracket 14. In the installed position shown in FIG. 5, the head portions 82 of the pedal end caps 80 are interposed between the flared end portions 70 of the hub 40 and the flanges 22 of the bracket 14. When the pedal assembly 18 is installed in the bracket 14, the pedal end caps 80 rotate with the hub 40 and serve as a spring washer axially interposed between the flared end portions 70 of the hub 40 and the bracket 14. It will be appreciated that the pedal end caps 80 advantageously eliminate any lateral gaps between the hub 40 and the bracket 14 to eliminate any lateral movement of the installed pedal assembly 18 relative the bracket 14 and to facilitate smooth and quiet operation of the pedal assembly 18. It will further be appreciated that this advantage is accomplished without the use of tools and without altering the simple snap-in attachment of the pedal assembly 18 to the bracket 14.

While the present invention has been described as carried out in specific embodiments thereof, it is not intended to be limited thereby but is intended to cover the invention broadly within the scope and spirit of the appended claims. 

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
 1. In a mounting for a control pedal on a motor vehicle for rotation about an axis, the combination comprising:a mounting bracket fixed relative to the vehicle and having first and second apertures defining the axis of rotation; the pedal having first and second bearings defining a pivot axis and a spring, wherein the first and second bearings are biased by the spring to axially outer positions and wherein the spring is compressible such that opposing forces on the bearings axially moves the bearings into axially compressed positions; wherein the spring forces the bearings in the axially outer positions when the pedal is positioned so that the bearings are exterior of the bracket; wherein the bracket forces the bearings in the axially compressed positions when the bearings are located within the bracket and not within the first and second apertures; wherein the spring forces the bearings in the axially outer positions when the bearings are in the first and second apertures, whereby the pedal snaps into the bracket; and a pair of pedal end caps disposed between the pedal and the bracket when the bearings are in the first and second apertures.
 2. A combination as claimed in claim 1, wherein the bracket includes first and second channels for axially aligning the pivot axis with the axis of rotation and for forcing the bearings into the axially compressed position.
 3. A combination as claimed in claim 1, wherein the bearings are rotatively fixed with respect to the bracket and the pedal end caps are rotatively fixed with respect to the pedal.
 4. In a mounting for a pedal in a motor vehicle for rotation about an axis, the combination comprising:a mounting bracket including two apertures defining the axis of rotation; and a pedal assembly having: a pedal, a hub having two radially outwardly flared ends, the hub rigidly fixed to the pedal and defining a pivot axis; two spring loaded bearings disposed within the hub, wherein the bearings automatically snap outward into the apertures of the bracket from a compressed first position to an extended second position when the bearings are aligned with the apertures, wherein the bearings rotatably connect the pedal with the mounting bracket; and two annular pedal end caps, the pedal end caps snap-fittedly engaging the ends of the hub and disposed between the hub and the mounting bracket when the bearings are aligned with the apertures.
 5. The combination as claimed in claim 4, further characterized by the bracket having facing guide channels for forcing the bearings into the compressed first position.
 6. The combination as claim in claim 4, wherein the bearings comprise plastic.
 7. The combination as claimed in claim 4, wherein the bearings are rotatively fixed with respect to the bracket and the pedal end caps are rotatively fixed with respect to the hub.
 8. The combination as claimed in claim 4 further comprising:spring pockets in facing surfaces of the bearings, and a coil spring disposed between the bearings and having ends disposed within the spring pockets of the bearings, wherein the spring loads the bearings.
 9. In a mounting for a pedal in a motor vehicle for rotation about an axis, the combination comprising:a mounting bracket including two laterally spaced apertures defining the axis of rotation; and a pedal assembly having: a pedal, a hub having radially outwardly flared end portions, the hub rigidly fixed to the pedal and defining a pivot axis, means disposed within the hub for rotatably connecting the pedal with the mounting bracket, and two annular pedal end caps having a conical head portion and a flexible skirt portion extending from the head portion, the head portions of the pedal end caps being disposed between the flared end portions of the hub and the mounting bracket when the pedal is rotatably connected with the mounting bracket, the skirt portions including radially reduced portions for snap-fitted engagement onto the flared end portions of the hub, and the hub with the snapped-on pedal end caps having a length less than the lateral spacing between the apertures of the mounting bracket.
 10. The combination as in claim 9, wherein the means is rotatively fixed with respect to the bracket, the hub is rotatively fixed with respect to the pedal, and the pedal end caps are rotatively fixed with respect to the hub.
 11. The combination as in claim 9 wherein the pedal end caps include a plurality of longitudinal slots extending partially through the head portions and entirely through the skirt portions to define flexible spring segments.
 12. The combination as in claim 11 wherein the flexible spring segments have radially outwardly tapered ends.
 13. The combination as in claim 11 wherein the pedal end caps comprise plastic.
 14. The combination as in claim 9 wherein the pedal end caps comprise plastic. 